Cable Assembly vs. Wire Harness: Understanding Their Differences

Before starting with the differences of a cable assembly vs. wire harness, it’s important to define a cable and a wire. Essentially, a cable is a bundle of wires with two or more insulated wires wrapped in one jacket. They’re often bonded or braided together, which is why you see cables that look like bunches of intertwined wires. Most cables contain a positive wire, a neutral wire, and a grounding wire. A wire, by contrast, is a strand of material that conducts electricity, such as aluminum or copper.

Five key differences between a wire harness and a cable assembly:

  1. Physical Attributes– The essential difference between a wire harness and a cable assembly is their physical attributes and function. A wire harness offers a cover that encases single cables, usually from the same material utilized in a cable assembly. One can see and remove an individual cable from a wire harness. In comparison, a cable assembly has multiple wires but is bundled together by a single external sleeve. It comes as a only one thick wire.
  2. Cost– Wire harnesses are a low-cost electrical solution that best keeps electric cables and wires organized. By bundling these wires and cables together, engineers can keep their wiring systems organized. It doesn’t concentrate on giving added protection to its wires and cables and usually requires less material and effort. Thus, it costs less compared to the cable assembly. Although cost-friendly, it still relies on the type, number, and quality of cables, wires, or connectors used in the production.

However, the cost of the cable assembly is satisfactory because of the added protection it provides. Cable assemblies offer more vigorous protection by keeping components snug within a rugged outer sheath. In addition, cable assemblies are intended to be utilized in demanding environments where things like heat, friction, or moisture could untimely wear out a cable or wire.

  1. Products – Many of our everyday household products and tools use wire harnesses. These products are computers, televisions, monitors, microwaves, and refrigerators. These products use wire harnesses rather than of cable assemblies because these products come with a protective shell, which removes the requirement for added protection. Wire harnesses are also present in most automobiles and airplanes.

Cable assemblies are used for severe environmental conditions or extreme temperature changes. In addition, many heavy industries such as medical, military, aerospace, and construction generally use cable assemblies in their manufacturing processes. They need the cable assembly to protect areas such as the electric flow in its wires or cables. They are the perfect for high-speed data transfers.

  1. Environments– Each is utilized in various environments. Wire harnesses provide minimal protection for wires. Its purpose is to organize wires and cables efficiently. It cannot shield them from extreme temperatures or friction between one another. They are fundamentally used for indoor use.

Cable assemblies guard all the products safe in the most extreme conditions and are ideal for outdoor use. It’s a high-level resistance to outside variables such as heat, dust, and moisture. It also protects the wire and cables from friction and corrosion.

  1. Purposes– Wire harnesses serve two primary purposes:
    1. To protect outside factors from harm caused by the flow of electricity.
    2. To ensure wiring systems are organized and straightforward for technicians to understand.

Cable assemblies serve three primary purposes:

  1. To protect outside factors from harm caused by the flow of electricity.
  2. To ensure wiring systems are organized and straightforward for technicians to understand.
  3. To protect the wiring or cable against wear and tear or other harsh environmental conditions.